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Expanded PVC User Guide

1. Celtec Thermal Expansion Contraction Because it is a cellular or foamed rigid polyvinyl chloride sheet product Celtec will expand or contract with an increase or a reduction in temperature as is common with all plastic materials When the temperature change is reversed the material returns to its original dimensions This property is called linear thermal expansion and contraction Because Celtec can be used in a wide variety of indoor and outdoor applications linear thermal expansion and contraction may need to be considered during the fabrication and installation of the material Important variables are the temperature at which the Celtec was machined as well as the temperature range of the environment in which the Celtec is installed In a location with a relatively constant temperature and not in direct sunlight such as an indoor display stand any thermal expansion and contraction of the Celtec material will usually not be significant If however a finished Celtec project will be used in a setting that has noticeable fluctuations in temperature the potential expansion and contraction should be considered when producing the part s Expansion of the Celtec material occurs when it is placed in an environment with higher temperatures than the temperature at which it was originally cut Conversely contraction or shrinkage of the material takes place when it is in a colder environment than that in which it was cut www acpla
2. Copyright 2005 A amp C Plastics Inc 5 8 Celtec User Guide 9 After exiting the laminator the coated substrates should be split apart and trimmed Figure 5f Recommended for Paper Liner Laminat 3 8 1 2 Gap Figure 5f After lamination the coated substrate may be split apart and further trimming may be accomplished Coating using Double Release Liner Films Coating with double release liner film such as Sealeze OptiMount UV or Print Mount Double requires the use of a take up mechanism to automatically remove and rewind one of the release liners during the coating procedure 1 Set the pressure properly for the thickness of the substrates to be processed 2 Load the supply roll of pressure sensitive adhesive such as Sealeze OptiMount UV and Print Mount Double 3 Adhere double stick tape or a pressure sensitive adhesive film such as Sealeze Print Mount or Print Mount Ultra to the surface of the take up shaft 4 Pull approximately 18 inches of adhesive film forward off the roll and adhere one release liner side smoothly to the take up shaft taking care to ensure that the film is square with the supply roll and no diagonal wrinkles are apparent Figure 5g www acplasticsinc com Chapter 5 Special Applications 5 9 4 Figure 5g Care must be taken to ensure _Take up Shaft____ film is squared to the supply roll or diagonal wrinkles will result Adhesive Film 5 Separate the
3. Beige 48x96 48x96 400C Yellow 48x96 48x96 123C 48x96 48x96 355C Red 1870 Red 1870 Blue 287C Light Blue 2935C Orange 48x96 21C Violet 48x96 Violet C ia 7 o ii B MN Ml Ultra Fade Resistant Red Ultra Fade Resistant Blue 48x96 48x96 E Copyright O 2005 A amp C Plastics Inc vi Celtec User Guide Celtec Displayboard 10mm 25mm Available Thicknesses metric Sheet Sizes inches Color PMS 48x96 ie 48x96 48x96 48x96 stat 48x120 nea 48x120 48x120 48x120 Jezo 48x96 48x96 48x96 Black 48x120 48x120 48x120 48x96 48x96 Grey 8C 48x120 48x120 www acplasticsinc com Processing This chapter details various methods of cutting Celtec as part of processing the material into its final form Common metal and woodworking tools and machinery can be used depending on the specific application for the finished product Cutting Sheets of Celtec up to 3 mm thick can be cut with a utility knife To cut sheets thicker than 3 mm band saws table saws and panel saws can be used as detailed later in this chapter Power shears and guillotines can crush the edges of Celtec sheets and generally produce unacceptable results With any cutting procedure frictional heat can build up and produce unacceptable results on cut edges Rough edges can also occur from cutting the Celtec using inadequate support or from using worn tooling For best res
4. Samuel Cabot The Finish 1700 Acrylic low lustre Series exterior Sherwin Polane E 5 0 VOC High Gloss V66V29 R7K338 Williams Flexible Polyurethane Enamel Exterior Polane HS Plus 2 8 VOC High Gloss V66V55 Polyurethane Enamel Exterior Polane S Plus 2 8 VOC Low Gloss V66V55 Polyurethane Enamel Exterior Polane T 60 2 8 VOC Low Gloss V66V90 Polyurethane Enamel Interior Spraylat Lacryl 400 Acrylic Lacquer i Lacryl 800 Acrylic Lacquer Copyright 2005 A amp C Plastics Inc 4 10 Celtec User Guide T J Ronan Bulletin Color Alkyd Enamel Prime All All Requires the use of 521 111 Elastiger Plus Topcoat Requires the use of 47 444SP Brushing Rolling Additive Requires R7KB4 solvent needed www acplasticsinc com Chapter 4 Graphic Applications 4 11 Paint Manufacturers Akzo Nobel Coatings Inc 770 662 8464 5555 Spalding Dr www azkonobel com Fax 770 662 5936 Norcross GA 30092 BASF Corporation 973 426 2600 3000 Continental Drive North www basf com Fax 973 426 2610 Mount Olive NJ 07828 1234 Blue River Coatings 888 420 2628 2910 South Nebraska Ave www bluerivercoatings com Fax 336 812 9036 Hastings NE 68901 Carbit Paint Company 800 288 2320 927 West Blackhawk St www carbit com 312 280 2300 Chicago IL 60622 2519 Fax 312 280 7326 Hydrocote Finishing Products 800 229 4937 61 Berry St Inc 732 828 7448 Somerset NJ 08873 www hydrocote com Fax 732 828 7325 Matthews Paint Company 800 323 6593 L
5. 2 14 Celtec User Guide se Je Pp ppp Satellite City Hot Stuff Super T Special T Se Schwartz Chemical Company fver ve2 o VC2 TEC Specialty Products Inc Max Bond reinforcing bond x x x x x x with mechanical fasteners www acplasticsinc com Chapter 2 Fastening 2 15 Recommended Adhesive Manufacturers 3M Adhesives Division 800 362 3550 3M Center www 3m com adhesives 651 733 1110 Building 220 8E 05 Fax 651 733 9973 St Paul MN 55144 1000 Cookson America 800 327 8460 1661 Old Dixie Highway Riviera Beach FL 33404 Daubert Chemical Co 800 688 0459 4700 S Central Avenue www daubertchemical com Fax 708 496 7367 Chicago IL 60638 Dow Corning Corporation 800 248 2481 Product Information Dept www dowcorning com 989 496 6000 PO Box 994 Fax 989 496 6974 Midland MI 48686 0994 GE Silicones Inc 800 255 8886 260 Hudson River Road www gesilicones com 877 943 7325 Waterford NY 12188 Fax 518 233 3529 Henkel Loctite Corporation 800 562 8483 1001 Trout Brook Crossing www loctite com 860 571 5100 PO Box 4016 Fax 860 571 5465 Rocky Hill CT 06067 National Casein 773 846 7300 601 West 80th St www nationalcasein com Fax 773 487 5709 Chicago IL 60620 Oatey Company 800 321 9532 4700 West 160th Street www oatey com 216 267 7100 Cleveland OH 44135 Fax 216 267 6538 Sashco 800 289 7290 10300 107 Place www sashco com Fax 303 286 0400 Brighton CO Satellite City 805 522 0062 PO Box 836 www caglue com Fax 805 572 9114
6. 2005 A amp C Plastics Inc Special Applications Celtec s light weight strength and versatility allow it to be used in many special applications Celtec is an effective core material for panel constructions using common synthetic resins or a wide variety of structural adhesives or plastics Celtec s smooth surface and adherence capacity make it an excellent choice for photomounting and laminating whether by hand for small jobs or with automated equipment for larger production runs Photomounting Celtec offers an excellent surface for mounting numerous materials including Cibachrome prints lithographs blueprints tissues and nearly all types of other papers Figure 5a Because of its strength and rigidity a stronger finished product is produced using Celtec as compared to other available substrate materials For example the corners of a Celtec photomounting application will not bend or crease as will items mounted on cardboard or foam type materials One significant advantage for photomounting is Celtec s smooth finish relative to other thermoplastics This finish allows prints to be easily repositioned or other mounted materials to be removed when necessary Once the mounting process is complete Celtec can be laminated and then routed heat bent drilled silk screened or painted for use in virtually any display application 5 2 Celtec User Guide 4 Figure 5a Mounting a print to Celtec using a sheet adhesive Ad
7. Expose approximately 1 of the adhesive Fold back the release paper in an even crease Adhesive 1 Exposed 3 Carefully position the print on top of the substrate using the folded release paper to prevent contact with the exposed adhesive Figure 5e Once positioned correctly carefully apply the print to the exposed adhesive pressing from the center toward the edges to ensure a smooth tack 4 Figure 5e Carefully position the print and apply the print to the exposed Celt ris adhesive strip Adhesive www acplasticsinc com Chapter 5 Special Applications 5 7 Place the direction switch in the forward position and the speed control on medium Insert the materials to be processed into the laminator opening Depress the foot switch and feed the substrate between the rollers until the pressure roller rests on the tacked portion of the material Hold the untacked portion of the print up and against the pressure roller Depress the foot switch to feed the substrate through the rollers while peeling the release paper off the mounting substrate with one hand To prevent wrinkles the print must be held against the roller with the opposite hand while the substrate feeds through the press Remove the mounted print from the rear of the laminator and trim it to the required size Coating using Single Release Liner Films 1 Set the pressure properly for the thickness of the substrate s to be
8. adhesive film from the release liner secured to the take up shaft and pull the adhesive film and remaining release liner down so that it rests adhesive side up on top of the pressure roller 6 Lay a leader board the same thickness as the substrates to be used across the exposed adhesive film and smoothly adhere the bottom of the leader to the adhesive Cold Laminating with VacuSEAL Press This method is suggested for small and medium sized photo shops for mounting prints utilizing a spray adhesive such as 3M Vac U Mount 1 Spray the adhesive such as Vac U Mount on the back of the piece to be mounted keeping the spray six to eight inches from the surface If using a double coat of adhesive the second coat should be applied in a direction perpendicular to the first coat For bonding most art materials the adhesive is typically applied only to one surface usually the back of the print 2 Allow the spray to dry two to four minutes before mounting so that the adhesive becomes tacky If blisters occur from trapped solvent allow the adhesive to dry slightly longer than four minutes 3 Position the print on the Celtec material and place inside the VacuSEAL vacuum frame 4 Apply vacuum for 10 minutes Copyright 2005 A amp C Plastics Inc 5 10 Celtec User Guide Hand Laminating using Transfer Adhesive For small shops or display makers without access to presses this method can be used for the lamination of flat relative
9. and a jig Strip Heater Heated Area To Be Bent To form tighter bends with smaller radii use a small heated area on the upper surface inside the bend of the Celtec sheet and a larger heated area on the bottom surface on the outside of the bend of the sheet A minimum radius of twice the sheet thickness is necessary to avoid breakage Figure 3b When bending Celtec into an angle typically the extension of the Celtec on either side of the angle should be at least 20 times the thickness of the Celtec material For example 6 mm 1 4 Celtec would require the extension on each side to be 120 mm 4 3 4 in order to avoid warping of the material For sides less than 20 times the material s thickness the entire sheet must be heated 4 Figure 3b Minimum recommended radius of two times the Celtec sheet thickness Minimum Radius 2X Material Thickness Once the Celtec 1s bent place it in a fixture such as a jig or clamp to cool Fans and or compressed air will speed the cooling process www acplasticsinc com Chapter 3 Forming Welding 3 3 Pressure or Drape Forming Celtec can be heated using radiant heat panels or air circulating ovens Either male or female molds can be coupled with plug assists or forced air to form parts Figure 3c This procedure is recommended for simple shallow forms with low definition Conventional equipment used for other thermoplastics is also ideally suited for Celtec Female For
10. are also critical Because force must be applied equally across the material the top roll must move evenly from left to right while maintaining even contact between top and bottom laminating rolls To achieve even contact zero the nip then use spacer shims to preset the nip opening for a particular laminate Use sufficient pressure to completely eliminate any air bubbles between the Celtec material the adhesive and the print or other material Cold Laminating Pressure 4 Figure 5b 25 40 PSI To use cold lamination with a pressure sensitive adhesive a force of 25 40 psi is required Adhesive Sheet The lamination will achieve maximum bonding in three hours If the lamination has been performed properly the finished mount can be flexed without the print becoming loose in the center To prevent moisture from becoming trapped between layers of porous material such as paper and creating blisters the level of moisture in both the material to be laminated and the atmosphere should be reduced before pressing Some materials may require predrying Celtec is nonporous and does not need predrying Copyright O 2005 A amp C Plastics Inc 5 4 Celtec User Guide Avoid hanging tacked pieces upside down for longer than 10 minutes as the prints may absorb moisture and change in dimension causing bubbles and wrinkles in the finished product Preventing Surface Blemishes Surface blemishes such as wrinkles can be caused by misal
11. handling It has low flammability and good chemical resistance to meet or exceed industry standards for a wide variety of applications including exhibits displays signs and theater props Celtec applications are limited only by your imagination We are always eager to learn about new and exciting applications Please contact our marketing department if you discover a creative new use of Celtec The inherent properties of Celtec eliminate time consuming and costly surface preparation In addition the material can easily be cut joined and fabricated with a wide variety of adhesives and ordinary fasteners and using readily available hand tools Celtec can be milled and routed like wood and often more quickly Because there are no knots there is very little likelihood of voids or holes in the mid wall Celtec is free foam and therefore does not have the inherent problems of voids that the celluka process does Celtec Displayboard has a very small cell structure enabling superior edge finishing and routing By varying the feed rates and speeds ii Celtec User Guide you can attain a very smooth edge When an even smoother edge is necessary sanding and planning can be performed as can laminated edge finishing Celtec also offers superior thermal properties and low thermal conductivity as well as high insulation and sound absorption qualities See the Engineering Specifications section of this manual for detailed information As a rigid and
12. index values of approximately 28 and above should not continue burning after the flame source is removed because the normal atmospheric oxygen content is insufficient to support combustion Impact Resistance and Environmental Stress Effect of Temperature With decreasing temperature there is a tendency towards decreased impact resistance Samples of 3 mm Celtec were conditioned in a freezer to a temperature of 10 C for a period of twelve hours The test bars were then impacted per ASTM D266 Charpy Impact Test Method B Specimens Unnotched The Cold Break specimens retained 85 of the original room temperature impact strength Copyright 2005 A amp C Plastics Inc Celtec User Guide Celtec Other Leading Brands 16X Magnification 16X Magnification Surface Surface Su rface Cross section Cross section Cross section Cellular Foamed Vinyls There are two types of cellular foamed vinyls open cell and closed cell In the closed cell type each cell is individual usually spherical in shape and completely enclosed by plastic walls This type of cell structure has good insulating properties as well as a high degree of buoyancy In the open cell type all the cells are interconnected This type of cell structure is known for its absorbency and capillary action Source Encyclopedia of PVC Vol 2 Page 619 A rigid foam PVC sheet or profile that is extruded via a free expansion process would thus be consider
13. longer the length of the bevel the smoother the resulting cut The bevel can be one of three basic types center inside or outside A center bevel is honed from both sides producing a V shaped point with each leg of the V being equal A modified center bevel or facet cut bevel is recommended for cutting Celtec To create a facet cut bevel the V of a center bevel is honed a second time giving the lead cutting edge a more obtuse angle Figure 1d 4 Figure 1d The two types of center bevels Center Facet Cut Bevel Bevel With either a center bevel or a facet cut bevel the longer the bevel length and the thinner the knife the more vertical the perimeter cut When both the inside and outside parts of a cut must be used such as with jigsaw puzzle pieces a center bevel is suggested because the resulting cut is wedge shaped thus giving both the inside and outside pieces an identical sloped cut An inside bevel has the honed side on the outside of the cut the scrap side while the straight unhoned side is on the inside of the cut or good side www acplasticsinc com Chapter 1 Processing 1 7 An outside bevel reverses an inside bevel It produces a straight cut on the inside or good part and a sloping cut on the periphery or scrap side Figure le Outside Bevel Inside Bevel Center Bevel a Figure 1e Typical bevels are designated as inside outside or center depending on where the honed surfac
14. measured 3 16 inside the tip of the gun The volume of air should be 50 liters per minute using a flow regulator with welding pressure at approximately 2 to 3 1 2 lbs depending on the rod diameter Following these guidelines welding speeds between 11 to 20 inches per minute are possible Skiving off the weld join for aesthetic purposes will reduce weld strength Copyright O 2005 A amp C Plastics Inc 3 8 Celtec User Guide Manufacturers Bending and Forming Equipment C R Clarke 8 Co Inc 800 676 7133 1106 Celebration Avenue www crclarke co uk 407 566 0755 Kissimmee FL 34747 Fax 407 566 0756 Kamweld Technologies Inc 781 762 6922 90 Access Road www kamweld com Fax 781 762 0052 Norwood MA 02062 Wegener North America 630 789 0990 16W231 S Frontage Road Unit 12 www wegener na com Fax 630 789 1380 Burr Ridge IL 60527 Thermoforming Equipment Brown Machine LLC 989 435 7741 330 North Ross St www brown machine com Fax 989 435 2821 Beaverton MI 48612 Lamco Machine Tool Inc 252 247 4360 135 Industrial Drive www lamcomachine com Fax 252 247 4633 Morehead City NC 28557 MAAC Machinery Corporation 630 665 1700 590 Tower Blvd www maacmachinery com Fax 630 665 7799 Carol Stream IL 60188 Plasti Vac Inc 800 438 4139 P O Box 5543 www plastivac com 704 334 4728 Charlotte NC 28225 Fax 704 334 0251 Line Bending Equipment Big Chief Supply Company 513 271 7411 5150 Big Chief Dr Fax 513 271 0790 Cincinnati OH 45227 Cr
15. of color fastness desired weathering requirements and surface preparation such as ultraviolet clearcoat Manufacturers have conducted tests of fade resistance for time periods ranging from just three months exposure to 30 months While test results vary one conclusion is obvious the nature of PVC material in untreated or natural form makes it susceptible to color fade due to UV exposure over time regardless of color or brand name In one study material samples in white red and blue produced by three different manufacturers were tested for 30 months readings taken with the Hunterlab color meter system using L a b color coordinates Very significant changes were seen in almost all samples except white with changes of more than five Delta E units considered dramatic Delta E quantifies the change in the three dimensional attributes of the Hunterlab color system for a measurement of total color difference from initial time of exposure In fact white material changes in a similar way but because the primary change is chalking the change is not as noticeable There are several ways to reduce or eliminate the impact of color fading in foamed PVC material One is to use white material itself in which the fading is less noticeable Other solutions include using a UV resistant clear topcoat using the foamed PVC material as a substrate for a vinyl film laminate or covering and painting the material with a weather res
16. other paints suitable for PVC For best results use a high quality 100 acrylic paint One interesting development that has shown great benefits in painting for outdoor applications is the UV reflective paints available through Blue River Coatings and Reno Coatings Test data shows that the surface temperatures are dramatically decreased which helps reduce expansion and protects the material for a longer lasting sign These UV reflective coatings are especially beneficial when a darker color is needed for a sign or display Care should be taken to follow the manufacturer s procedures and always test a small piece in the application before final preparations are made See the Paint Manufacturers table and the addendum at the end of this chapter for contact information and test data Most enamels and water based systems are generally not recommended for Celtec Conventional equipment may be used to apply varnish to Celtec Before applying varnish Celtec sheets should be wiped or treated with an antistatic solution or solvent wipe to ensure that the surface is clean and properly prepared Be sure to follow the manufacturer s instructions for thinning concentrated forms of varnishes Apply paint or varnish in only one direction ifusing a brush Figure 4a Celtec material generally requires only one coat of varnish 4 Figure 4a To obtain optimum results for brush applied paints and varnishes apply coats in one direction and air dry ac
17. spraying equipment can be used on Celtec material Figure 4e Paints and varnishes may also be applied with a paint brush or roller www acplasticsinc com Chapter 4 Graphic Applications 4 7 4 Figure 4e When spray painting complete all passes in one direction first then make additional passes at 90 to the first Spraying hints Do not use airless spraying equipment Air operated equipment such as DeVilbiss spray finishers 1s preferred Use a spray nozzle with a 30 air cap to disperse the paint properly Set the air pressure on the material at 24 psi and 40 50 psi on the air cap Keep the spray gun nozzle perpendicular to the surface of the material Make three spraying passes in one direction turn the panel 90 and make three additional passes Lightly sand any runs that occur on the edges of the Celtec with 200 grit sandpaper and touch up with additional paint or varnish as needed Vinyl Lettering When applying text to Celtec pressure sensitive or static cling vinyl letters are highly recommended As with other graphic applications the surface of the Celtec material must be free of dust or other small particles degreased and dry before applying lettering Copyright 2005 A amp C Plastics Inc 4 8 Celtec User Guide Specifications Recommended Silkscreen Inks for Celtec CC raene AI ACT EAT NazDar Solvent based 200 305 System 2 Solvent based 200 305 2700 Water 200 305 MP M
18. temperature in the environment in which the Celtec part 10 F will be used in degrees Fahrenheit 3 Total temperature difference subtract line 2 from line 1 4 Total length of Celtec part in inches 5 Total amount of contraction in inches line 3 x line 4 x 0 00004 0 230 in Using the worksheet and converting the results to fractional inches the maximum amount of expansion of the 96 part will be approximately 1 8 and the minimum amount of contraction will be approximately 1 4 To allow for this expansion and contraction the Celtec sign should not be fastened directly to the concrete exterior wall as it might then buckle crack or warp during temperature fluctuations In this example slots for fasteners Copyright 2005 A amp C Plastics Inc 2 6 Celtec User Guide or U channel tracking should be cut to allow the part to expand up to 96 1 8 and contract to 95 3 4 Celtec Linear Expansion Contraction Quick Reference Expansion Contraction of Material at Standard Lengths Widths Total in inches Temperature Change 48 Inches 120 Inches 0 038 0 096 40 F 0 077 0 192 60 F 0 115 0 288 80 F 0 154 0 384 100 F 0 192 0 480 120 F 0 230 0 576 140 F 0 269 0 336 0 538 0 672 Screwing and Nailing Any type of screw or nail can be used to fasten Celtec material pre drilling is typically unnecessary Power nailers and screw driving equipment are suggested Inserting the screw or nail
19. to the top or bottom platen of the press Hydraulic Top Platen Ejection x w Celtec Backup Plate y Strips MA AA Ejection Strips a Figure 1b Strips of a resilient material help eject Celtec material from the die For best results dull or worn knives should be replaced as needed with new ones Factors affecting die cut quality Temperature of the Celtec material Celtec is a thermoplastic which has a tendency to be more brittle at lower temperatures When the Celtec sheet temperature is below 75 F the first two thirds of the cut is clean while the Copyright 2005 A amp C Plastics Inc 1 4 Celtec User Guide last third exhibits fracturing When the Celtec material is heated above 75 F the quality of the cut improves and fracturing is reduced The best result is achieved when Celtec is preheated to 100 F For complex die cut parts a higher temperature during cutting will reduce the likelihood that fracturing of the Celtec will occur Sheet thickness The quality of the die cut is also affected by the material s thickness The best cuts are produced using Celtec sheets of 3 mm or less Die cuts in Celtec sheets over 4 mm tend to exhibit deformation roughness along the cut edge and or fractures in the material To cut Celtec 1 Verify that the SRD has the proper point value and bevel 2 Preheat the material to 100 F 3 Select the appropriate backup plate 4 Maintain a sharp cutting edge
20. will be used in degrees Fahrenheit 3 Total temperature difference subtract line 2 from line 1 4 Total length of Celtec part in inches 5 Total amount of contraction line 3 x line 4 x 0 00004 Conversion Table Decimal to Fractional Inches 0 032 1 32 0 156 5 32 0 281 9 32 0 406 13 32 0 063 1 16 0 187 3 16 0 312 5 16 0 438 7 16 0 093 3 32 0 218 7 32 0 343 11 32 0 469 15 32 0 125 1 8 0 250 1 4 0 375 3 8 0 500 1 2 www acplasticsinc com Chapter 2 Fastening 2 5 Celtec Thermal Expansion Contraction Worksheet Example A Celtec part is cut in a shop where the temperature is 70 F The part is 96 inches long The part will be installed as part of an outdoor sign on a concrete building The highest expected temperature after installation is 100 F and the lowest expected temperature is 10 F 1 Highest expected temperature in the environment in which the Celtec 100 F part will be used in degrees Fahrenheit 2 Approximate temperature of the Celtec part at the time it was cut in 70 F degrees Fahrenheit 3 Total temperature difference subtract line 2 from line 1 4 Total length of Celtec part in inches 5 Total amount of expansion in inches line 3 x line 4 x 0 00004 0 115 in Contraction 1 Approximate temperature of the Celtec part at the time it was cut in 70 F degrees Fahrenheit 2 Lowest expected
21. with a lint free cloth Always use PVC screen inks and thinners from the same product line and manufacturer Incompatibility of inks and thinners may cause surface cracking and reduce the life span of the Celtec material A sample of Celtec should be flood screened prior to production to ensure a finished product of acceptable quality Painting Varnishing Although Celtec requires no painting any painting planned for a project should be completed as soon as possible either during or soon after the construction process Priming is not mandatory but should be performed prior to painting if the paint manufacturer s warranty is a consideration In order to avoid heat buildup light paint colors are recommended for most applications Sheets of 19mm and greater thickness can accept slightly darker colors but not very dark i e black brown forest green etc Paint adheres to Celtec material exceptionally well In general no primers are needed to prepare the Celtec sheet for painting although the surface of the Celtec should be dry clean and degreased for best results Any method of paint application may be used including power or manual rollers spray guns conventional brushes sponge type brushes artists lettering brushes and or dipping Celtec sheets are painted most successfully with vinyl paints non water based acrylic lacquers two component polyurethanes and www acplasticsinc com Chapter 4 Graphic Applications 4 3
22. 11 2811 S Harbor Blvd www arlon com Fax 714 540 7190 Santa Ana CA Kapco Graphics 330 678 1626 1000 Cherry St www kapcographics com Fax 330 678 3922 Kent OH 44240 ORACAL USA 904 726 9597 7251 Salisbury Rd www oracal com Fax 904 726 9409 Jacksonville FL 32256 www acplasticsinc com Chapter 4 Graphic Applications 4 13 Addendum Test Data for Reno Coatings Prolux Series 32000 Three pieces of 1 1 2 Celtec Displayboard Foam PVC were cleaned and coated with Prolux Series 32000 brown paint After 30 minutes of air drying the pieces underwent two hours of forced drying at 110 F After 10 days the three samples were tested for adhesion and showed complete adhesion of the paint to the substrate The pieces were also tested for resistance to heat buildup using a 250 watt infrared lamp The samples were placed under the lamp with the painted surface facing the lamp at a distance of 13 inches After one hour the maximum temperature reached by the surface was 160 F hottest spot measured with an IR gun The three samples performed very well with no change or deterioration at the surface no blistering of the paint and no deformation of the substrate A similar high quality brown paint but with no heat reflective properties was applied to the other side of the samples Upon performing the same heat exposure test the hottest spot reached 230 F and there was a slight deformation of the surface at that area Copyright
23. C Plastics Inc assumes any legal responsibility Our warranties are limited to those expressly stated in written contracts or in conditions of sale As conditions and methods of use vary and are beyond the control of A amp C Plastics Inc A amp C Plastics Inc disclaims any liability incurred as a result of the use of its products in accordance with the data contained on our physical properties charts or in our manual No information herein shall be construed as an offer of indemnity for infringement or as a recommendation to use the products in such a manner as to infringe any patent domestic or foreign Copyright 2006 A amp C Plastics Inc This page intentionally left blank www acplasticsinc com Celtec User Guide INTOUCION ii rodea T i Product Availability urna naci i iii Chapter 1 Processing Cutt gs 4c 2 konna dh anne aha Ane ARN eRe eR RAN as Cae BR aioe 1 1 Die Cutting a A A Ameena Meena eeteon 1 1 O O cheat E toes EAE Ee aeS E N TEN a o ee 1 12 Dia A Ad 1 13 Mil ri 1 14 ROUNE A tas 1 14 Edge Finishing cto talas o one Matin dla Do abled ter letales al o ont Aga AMAIA 1 15 Manufacturer EL 1 16 Chapter 2 Fastening INLEI NON RTIA AAT A cotas o A tence ren Seat li os da rt teta 2 1 Celtec Thermal Expansion Contraction ccccesccsseseseeseeeseeeseeseceeeeseensecesecaecaaecsaecaeeeaeeeaeeneeeneeeas 2 2 Celtec Thermal Expansion Contraction Worksheet ccccccssesscsesceeeeeseceseceseeseecae
24. Expanded PVC User Guide Celtec User Guide o PLASTICS INC Service It s what we deliver 1 800 231 4175 www acplasticsinc com No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical electronic photocopying recording or otherwise without prior written permission of A amp C Plastics Inc 2005 by A amp C Plastics Inc All rights reserved www acplasticsinc com All information contained herein is accurate to the best of our knowledge and is provided without liability or commitment whatsoever All recommendations or suggestions are made without guarantee since the conditions ofuse are beyond our control We recommend that you confirm the suitability of our product by carrying out tests under your local conditions and using your own mechanical equipment We disclaim any liability incurred in connection with the use of these data or suggestions This publication is not to be taken as a license to operate under or a recommendation to infringe any patents The observance of all legal regulations and patents is the responsibility of the user Processing and finishing techniques are presented as typical Information contained herein is considered accurate to the best of our knowledge It is offered for your consideration and investigation and is not to be construed as a representation or warranty expressed or implied for which A amp
25. For material over 4 mm thick additional steps such as sanding or routing may be necessary after die cutting to smooth any rough edges produced by the cut The thickness of the Celtec material will also affect the quality of the die cut when the piece has one or more small radii As the thickness increases the difficulty involved in producing smooth cuts with small radii also increases Sheets 4 mm thick or less can be die cut using a radius as small as 1 8 inch Knife thickness As the knife edge penetrates the Celtec it exerts an enormous compressive force which can produce deformation or rounding of the material s corners The knife s penetration also creates a shearing force which tends to cause fracturing of the material approximately two thirds of the way through the Celtec sheet Applications that require cutting of narrow radii or U shaped tabs are highly susceptible to shearing because of the severe lateral pressure The selection of a correct gauge point thickness for the knife material is critical for any die cutting operation For example straighter smoother cuts involving small radii are more readily achieved using a thinner rather than thicker gauge knife steel assuming that both knives have the same bevel configuration and angle However a thinner knife is more vulnerable to warping bending or breaking because of the extreme compression when the Celtec is thick especially when the sheet is below 100 F www acplas
26. Simi Valley CA 93062 Schwartz Chemical Company 718 784 7592 50 01 Second St Long Island City NY 11101 Copyright 2005 A amp C Plastics Inc 2 16 Celtec User Guide Additional Adhesive Manufacturers Bostik Findley Inc 800 726 7845 211 Boston St www bostik com 978 777 0100 Middleton MA 01949 2128 Henkel Adhesives 847 608 0200 1345 Gasket Dr www henkeladhesives com Fax 847 608 0212 Elgin IL 60120 IPS 800 421 2677 455 W Victoria Street www ipscorp com 310 898 3300 Compton CA 90220 Liquid Nails a division of ICI Paints www liquidnails com 800 634 0015 925 Euclid Ave Cleveland OH 44115 Parabond 800 742 1431 600 Ellis Rd www parabond com Durham NC 27703 TACC a division of Illinois Tool O www taccint com 800 503 6991 Air Station Industrial Park 516 623 6000 Rockland MA 02370 Fax 516 867 1060 Additional Manufacturers of Adhesives Specific to Celtec 550 AmBel Corporation www excelglue com OSI Sealants Inc www osisealants com Siroflex Inc www siroflexinc com White Lightning a division of Diversified Brands www diversifiedbrands com 800 779 3935 P O Box 819 318 876 2495 188 Cottonport Ave Fax 318 876 2213 Cottonport LA 71327 800 321 3578 7405 Production Dr Fax 800 227 6095 Mentor OH 44060 800 359 6398 1320 Garlington Ra 864 458 9094 Greenville SC 29615 Fax 864 458 9092 800 777 2966 101 Prospect Ave Fax 800 243 3075 Cleveland OH 44115 www acplasticsin
27. Y 0 White 0 B 0 K 0 FFFFFF C 60 M 63 R 61 o G 51 g Black Black B 43 K 60 3D332B C 0 M 0 R 136 G 138 Yoo Grey Gray 8C B 140 K 56 888A8C C 23 M 19 R 196 i G 193 Y 24 Cool Grey Cool Grey 4 B 186 K 0 C4C1BA C 18 M 19 R 209 G 198 Y 27 Beige Beige 400 B 181 K 0 D1C6B5 C 1 M 22 R 255 G 198 Y 95 Yellow Yellow 123 B 30 K 0 FFC61E C 84 M 11 R 0 Green Green 355 B 73 K 1 009E49 C 22 M 100 R 175 G 30 Yz Red Red 187 B 45 K 13 HAF1E2D C 100 M 69 R 0 G 56 Y 0 Blue Blue 287 B 147 K 11 003893 C 90 M 68 R 0 Light Blue G 91 Y 0 Light Blue 2935 B 191 K 0 005BBF C 2 M 71 R 239 G 107 Y 100 Orange Orange 21 B 0 K 1 EF6B00 C 94 M 91 R 102 G 7 Y0 Violet Violet C B 165 K 0 6607A5 www acplasticsinc com Product Availability Celtec Displayboard Product Availability Celtec Displayboard is a rigid foamed PVC sheet with a satin finish Celtec is available in twelve 12 standard colors and gauges from 1mm to 25mm The tables below show the product availability for 1mm 6mm and 10mm 25mm Color PMS Available Thicknesses metric Sheet Sizes inches AENA A E White 48x96 48x96 48x120 60x120 Black 48x96 48x96 48x120 60x120 ewa IES 48x96 48x120 60x96 60x120 48x96 48x120 60x96 60x120 48x96 48x96 48x96 Y k 48x96 48x120 60x96 60x120 48x96 48x120 60x96 60x120 48x96 Cool Grey 4C
28. aftics Inc 505 338 0005 PO Box 91930 www craftics com Fax 800 289 2020 Albuquerque NM 87199 FTM Inc Westedge 530 626 1986 6160 Cobblestone Rd www 123ftm com Fax 530 642 2602 Placerville CA 95667 Watlow Electric Manufacturing Co 800 492 8569 12001 Lackland Rd www watlow com 314 878 4600 St Louis MO 63146 www acplasticsinc com Chapter 3 Forming Welding 3 9 Welding Equipment Kamweld Technologies Inc 781 762 6922 90 Access Road www kamweld com Fax 781 762 0052 Norwood MA 02062 Laramy Products Co Inc 802 626 9328 40 Sandy Lane www laramyplasticwelders com Fax 802 626 5529 Lyndonville VT 05851 Seelye Inc 800 328 2728 9700 Newton Avenue South www seelye plastics com 612 881 2658 Bloomington MN 55431 Fax 612 881 3503 Wegener North America Inc 630 789 0990 16W 231 S Frontage Road Unit 12 www wegenerwelding com Fax 630 789 1380 Burr Ridge IL 60527 Ultrasonic Equipment Dukane Corporation 630 584 2300 2900 Dukane Dr www dukane com Fax 630 584 2370 St Charles IL 60174 Copyright O 2005 A amp C Plastics Inc 3 10 Celtec User Guide This page intentionally left blank www acplasticsinc com Graphic Applications Celtec Displayboard performs outstandingly with a wide range of graphic applications including paints varnishes screen printing digital flatbed printers and vinyl films Celtec can be used to create weather resistant signs displays or Point of Purchase materials The smoo
29. akeView Corporate Park www signpaint com 262 947 0700 8201 100 Street Fax 262 947 0444 Pleasant Prairie WI 53158 One Shot LLC a subsidiary of 219 949 1684 5300 West 5 Ave Spraylat Corporation Fax 219 949 1612 Gary IN 46406 www 1shot com PPG Inc 412 434 3131 One PPG Place www ppg com Pittsburgh PA 15272 Reno Coatings Inc 450 621 7746 485 De L rabli re www renocoatings com Rosemere P Q Canada J7A 4M4 Samuel Cabot Paint 800 878 8246 See website for local distributor www cabotstain com Schwartz Chemical Company 718 784 7592 50 01 Second St Long Island City NY 11101 Sherwin Williams Company 800 336 1110 Contact local dealers www sherwinwilliams com Spraylat Corporation 914 699 3030 716 S Columbus Avenue www spraylat com Fax 914 699 3035 Mt Vernon NY 10550 Copyright O 2005 A amp C Plastics Inc 4 12 Celtec User Guide Manufacturers Primer Manufacturers Masterchem Industries 800 325 3552 3135 Highway M www masterchem com 866 Primer1 Imperial MO 63052 Fax 636 942 3663 One Shot LLC a subsidiary of 219 949 1684 5300 West 5 Ave Spraylat Corporation Fax 219 949 1612 Gary IN 46406 www 1shot com T J Ronan Paint Company 800 247 6626 749 East 135 St www ronanpaint com 718 292 1100 New York NY 10454 Fax 718 292 0406 Vinyl Graphics Manufacturers 3M Commercial Graphics 800 328 3908 3M Center Division Fax 651 736 4233 Building 220 6W 06 www scotchprint com St Paul MN 55144 Arlon 714 540 28
30. c com Chapter 2 Fastening 2 17 This page intentionally left blank Copyright 2005 A amp C Plastics Inc Forming Welding 3 Celtec can easily be shaped using conventional methods such as heat bending pressure forming and vacuum forming Because Celtec heats and cools very quickly the formed parts are cleanly and clearly defined making the material excellent for sign faces and point of purchase displays Heat Bending Celtec sheet material can be bent by using Calrods radiant heaters strip heaters Figure 3a or air circulated ovens Heat guns can also be used on small areas To ensure best results a rheostat should be used to control heating of the Celtec so that the surface temperature does not exceed 340 F Heating Celtec material over 340 F can cause the surface to become rough and possibly discolor When using a metal contact strip heater cover the heater strip with Teflon spray to prevent marking the Celtec Different sizes of rectangular heating bars can be used to produce bends of different radii The larger the heated area of the Celtec the larger the radius that can be created Celtec should be heated from both sides when the sheet is thicker than 4 mm Celtec heats much more quickly than solid PVCs or acrylics and requires heating at the rate of approximately 30 to 40 seconds per millimeter of thickness prior to bending 3 2 Celtec User Guide 4 Figure 3a Heat bending using a strip heater
31. contact Wegener North America Ultrasonic welding of Celtec is currently in the development stages For more information contact Edison Welding Institute Contact information can be found at the end of this chapter Hot gas welding can be performed with a hot air gun and welding rod Figure 3f The air should be clean and free of all contaminants If the air is not clean an inert gas such as nitrogen can be used The welding temperature and volume of air should be adjustable Celtec welds ideally with a Type II welding rod but also can be welded with a Type I welding rod The weld strength is approximately 60 of solid PVC Copyright 2005 A amp C Plastics Inc 3 6 Celtec User Guide Woicing 4 Figure 3f Welding e Heat welding of Gun Celtec Celtec SS The Celtec sheets to be welded should be free from dust or oil For butt welding using the hot gas method sheets should be chamfered using a table saw milling machine or router The angle should be 60 for round beads and 80 for triangle beads with corner welds at right angles Figure 3g The chamfer should be at 45 Double Bevel Butt Weld a 4 Figure 3g Heat welding cross sections Single V Butt Weld www acplasticsinc com Chapter 3 Forming Welding 3 7 To weld Celtec material feed the rod through the gun and apply pressure on the rod as the sheet and rod are heated simultaneously The temperature of the gas should be at 680 F when
32. cording to manufacturer s instructions One Direction Only Copyright O 2005 A amp C Plastics Inc 4 4 Celtec User Guide Celtec is a thermoplastic material that will deform at temperatures above 140 F and cannot thus be heat dried at high temperatures Air dry paints and varnishes are therefore most successful with Celtec material Most air dry varnishes dust dry in 30 minutes at room temperature and are completely dry after 24 hours Surface Preparation Before painting or varnishing clean the surface of the Celtec material with a clean cloth and an aliphatic solvent such as isopropyl alcohol heptane octane UM amp P or naphtha in order to produce good adhesion Remove any scratches on the Celtec material s surface by sanding with fine sandpaper or by rapidly fanning the area with a heat gun Once sanded the original finish is removed Cross Hatch Adhesion Test Good paint and varnish adhesion is critical to achieving a successful finished product The cross hatch adhesion test described below should be performed on every paint or varnish system unless it is specifically recommended for Celtec material For paint and varnish brands consult the list of recommended manufacturers at the end of this chapter Although most paints will feel dry to the touch after 24 hours some paints may not acquire full adhesion to the Celtec material for two to three weeks after application 1 Ona sheet of Celtec apply the paint
33. dity changes Delaminating A print mount can be delaminated within five minutes if a pressure sensitive adhesive such as MACtac IP 2000 or Seal Print Mount has been used Although the print is usually ruined the Celtec material can be reused If five minutes have already passed a hot air gun or a hair dryer can be used to heat the material in order to peel off the lamination Isopropyl alcohol or mineral spirits can be used to remove the remaining adhesive www acplasticsinc com Chapter 5 Special Applications 5 13 Manufacturers Photomounting Adhesive Manufacturers 3M Adhesives Division 800 362 3550 3M Center www 3m com adhesives 651 733 1110 Building 220 8E 05 Fax 651 733 9973 St Paul MN 55144 1000 DryTac Corporation 800 280 6013 5383 Glen Alden Drive www drytac com 804 226 3094 Richmond VA 23231 Fax 804 226 2330 Henkel Adhesives 847 468 0200 1345 Gasket Drive www henkeladhesives com Fax 847 608 0212 Elgin IL 60120 MACtac 330 689 8456 4560 Darrow Road www mactac com Fax 330 689 9841 Stow OH 44224 Photomounting Press Manufacturers Advanced Greig Laminators 608 846 1025 801 Burton Boulevard www aglaminators com Fax 608 846 1024 DeForest WI 53532 Robert L Greig Company 800 525 2701 P O Box 419 Stoughton WI 53589 Seal Graphics America 410 379 5400 7091 Troy Hill Drive www sealgraphics com Fax 410 579 8960 Elkridge MD 21075 Cold Mount Laminator Manufacturers Coda Inc 201 825 7400 30 Industria
34. e of the knife faces in relation to the finished shape Bevel sharpness Steels used for SRDs have a hardness of 57 59 Rockwell C After much use however the knife will dull and produce cuts of increasingly poor quality Resharpening knives is not recommended because it frequently results in an uneven edge and knife depth even when the sharpening is performed by a skilled machinist Even a slightly uneven edge will result in unequal penetration of the Celtec material and thus in a ragged cut Do not resharpen knife blades Always replace dull or worn knives with new ones to ensure even cuts The backup plate Steel is often used to fabricate backup plates because the plate must not be too soft However steel plates can sometimes cause incomplete penetration of the Celtec which also causes the material to fracture at the end of the cutting stroke One method of avoiding this problem is to use a backup plate made from a sheet of Celtec or of chipboard placed over the steel backup plate These softer materials enable the die to penetrate about 1 10 inch beyond the Celtec sheet producing a cleaner cut Figure 1f Copyright 2005 A amp C Plastics Inc 1 8 Celtec User Guide 4 Figure 1f A backup plate made of Celtec Steel Back up Plate or chipboard enables the die to penetrate the Celtec material to be cut Celtec Back up Material 4 10 Make ready Because of slight variations in thickness of a backup plate the degree of
35. eaner Depending on the type of application and the consistency of the adhesive the adhesive can be applied to the material with a brush a syringe or an eyedropper If cement is applied to one surface let the two surfaces be in gentle contact for a few seconds to allow the cement to soften the dry surface then press parts together in firm contact Figure 2e Copyright O 2005 A amp C Plastics Inc 2 10 Celtec User Guide 4 Figure 2e Bonding Celtec to another Adhesive substrate When using any adhesive system be certain to follow the manufacturer s storage and handling recommendations Disposing of spent adhesives or solvents may be subject to local regulations www acplasticsinc com Chapter 2 Fastening 2 11 Weld On Adhesive Selections The table below details the individual Weld On adhesives best used to bond Celtec to various materials Copyright 2005 A amp C Plastics Inc 2 12 Celtec User Guide Celtec Material Bonding Chart Weld On Product Number Material 1784 gt W 0 Acrylic Cell Cast Acrylic Cross Linked Acrylic Extruded Butyrate Concrete Fiberglass Metal PETG Polycarbonate Polyester Polyurethane PVC Rigid PVC Flexible PVC Foamed Styrene L e eE COPIES ACUI Ae CULE USL PICS e an e NAAA AAA eee e dde Wood Weld On Typical Product Viscosity Typical Number Color Body cps Sp Gr Weld On is a registered trademark of IPS Corpo
36. ed PVC Xenon EXP 300MJ 12 Months Florida O D NO O Brand Z Brand Y Green Beige ilies Ae Celtec Black ack White Lower Value Better Color Retention Oo Total Color Change Delta E nee Blue Yellow Production minimums for custom colors range between six and 45 metric tons depending on the pigment required custom or standard and the amount of start up time involving scrap generation that is needed to achieve the desired color Darker custom colors require a heavier pigment load That may also affect the other raw materials involved and affect the integrity of the product involving such Copyright 2005 A amp C Plastics Inc 6 6 Celtec User Guide factors as its density In turn some of the other variables already discussed can be affected These include the top and bottom surface finish of the sheet and perception of color Manufacturers typically request a signed off color sample written purchase order and acceptance of up to five Delta E units variation before they will provide the material While other materials such as acrylic and styrene offer smaller minimums they do not of course offer all the fabrication capabilities appearance and performance features that have led to the popularity of foamed PVC Available in a wide range of standard thicknesses it is the best substrate for screen printing and it can be painted usually without priming The properties of foam
37. ed PVC allow faster heat bending and thermoforming Special tools are not required for many fabrication steps such as cutting trimming or die cutting The material provides a rigid flat mounting surface and it can be laminated to other materials Its combination of economy and performance continues to make it an excellent value for a wide range of applications Each material has inherent characteristics which must be considered in the manufacturing process the nature of the material should also be fully considered in selecting and using it End users should be able to expect correct and straightforward information from manufacturers and distributors about such issues This will help to prevent misunderstanding and it will result in more successful projects That s good for all of us www acplasticsinc com Chapter 6 Engineering Specifications 6 7 Fire Characteristics Any material having an oxygen index in excess of 26 will not continue to burn when a flame source is removed The oxygen index of Celtec is 35 which makes it self extinguishing meaning that when the flame source is removed the burning stops It is important to remember that many other plastic materials and natural products such as wood have values under 26 High oxygen index ASTM D 2863 measures the percent of oxygen in an oxygen nitrogen mixture that barely supports burning The oxygen content of the earth s atmosphere is about 21 Materials with oxygen
38. ed a closed cell foam Examples of open cell types would be a foamable Plastisol or a sponge like flexible plastic foam as is used in cushions or padding for furniture www acplasticsinc com Chapter 6 Engineering Specifications 6 9 Specifications for Celtec Foam PVC Sheet Typical Physical Properties Property ASTM Method Celtec 700 Value Celtec 550 Value Water Absorption D570 0 15 Typical Mechanical Properties CI CI CI E o O Hold D1761 35 Lbf in of penetration Test result 156 3 4 thickness Nail Pulling 3 1 4 coated 16d nail D6117 Test result 204 1 thickness Screw Hold D1761 680 Lbf in of penetration Test result 519 3 4 thickness Screw Pulling 3 gold coarse screw D6117 Test result 723 1 thickness Staple Hold D1761 180 Lbf in of penetration Gardner Impact Gardner Impact D4228 Po 103 in lbs Izod Impact Strength pase 0 53 felb in Fe Charpy Impact Unnotched 23 C pase 8 1 ft Ib in 4 5 ftlb in Copyright 2005 A amp C Plastics Inc 6 12 Celtec User Guide This page intentionally left blank www acplasticsinc com Chapter 6 Engineering Specifications 6 11 Standard Specifications USDA Approved Incidental Contact Celtec can be used for sign needs wherever food is processed or sold It is lead cadmium and barium free U L Classified Celtec is the first foamed PVC to be U L Classified meeting all three U L 1975 fire tes
39. eeseeeeeeneeensenrens 2 3 Screwing and Nailing iii A ieee EE ei 2 5 A dbase Salted Bika psa ense dened ease ecg Lae Res RR tae ded eset 2 7 Bonding and Adhesives umi dc 2 8 Weld On Adhesive Selections ccccesccsssesseceseceseceeeseeeneeseceeeecensecaecaaeceaeceaecseeeaeeeaeeeneenneeaes 2 10 Adhesives and Manufacturers ccccccccssecssecseeeseesseessceeensecescensecaecnaecaeecaeeeneeeneeeeeseeeeesenereneenaeees 2 11 Chapter 3 Forming Welding Heat Bending RN O eee 3 1 Pressure or Drape Forming ceo oie cc ada 3 3 VU O a 3 4 PEO o sie besetee tee E Reese Ee ea eee ee 3 5 Mad ii 3 8 Chapter 4 Graphic Applications Cleaning Pretreatin ui ts is 4 1 Digital Flatbed Printing ais 4 2 Painting Varnis hing da 4 2 Va Vetter apta 4 7 SPECIPICAti OS i e SA E fetes e E e A O 4 8 Marita turers anti bros abevedac a acia 4 11 PA AG SHAUN i ste ots She A E E EE cases cd dlesesscesececedalsees asesgbicwssdsses tesseancel nes 4 12 Chapter 5 Special Applications PhoOtomountin id ede ees 5 1 AAA A dao 5 2 Laminating Techniques 1 A AA A AA ee ae da 5 5 MANU ACUTE eck iss oak ee fake ioe bd aes ea A E eles feces 5 13 Chapter 6 Engineering Specifications Weatherability Effects of Outdoor EXpOSure ooooocoioccnonononoonnoononnconoco nono nooo nnon nono nonnnonn ron rra nrnnnrnnnns 6 1 Hire Characteristics e te e 6 7 Specifications for Celtec Foam PVC Sheet coooooocoonocococononononoconononono nono nonnonononnnn nono n
40. eet per minute Feed 70 to 90 feet per minute Tooth pitch 0 080 to 0 040 4 Figure 1j Circular saw blade usage Celtec ees AS AA e Band Saws High speed steel blades normally recommended for wood or plastic hook type can be used for Celtec material within the following guidelines 4to 8 teeth per inch Cutting speed 3 000 to 5 000 feet per minute Feed up to 40 feet per minute Saber Saws Rough cut type blades ground for plastics can be used on Celtec sheets Smooth metal cutting blades however will not produce acceptable results www acplasticsinc com Chapter 1 Processing 1 13 Drilling Celtec can be drilled with carbide tipped bits using twist drills recommended for metals Figure 1k The following settings are recommended Point angle between 90 to 110 Spiral angle 30 Relief angle 10 Cutting speed 150 to 1 300 feet per minute Feed rate 0 01 to 0 02 inches per revolution Removing the drill from the Celtec material periodically may be necessary when drilling deeper holes so that frictional heat does not build up Drill bits ground for normal rigid PVC will not produce acceptable results For best results drill bits should be kept sharp at all times 4 Figure 1k Drill grinding specifications Point Angle 90 110 Copyright 2005 A amp C Plastics Inc 1 14 Celtec User Guide Milling Celtec can be milled by using standard milling machin
41. er millimeter in air circulating ovens Vacuum Forming Vacuum forming of Celtec is similar to pressure forming except that it is generally used when greater part detail and dimensional repeatability are necessary Figure 3e The forming temperature for Celtec is also higher generally 330 F to 340 F Exceeding 340 F is not recommended because it can cause bubbling of the Celtec surface www acplasticsinc com Chapter 3 Forming Welding 3 5 4 Figure 3e Vacuum forming Vacuum Forming Molds for vacuum forming are generally made of wood or plaster for short life short runs and of nonferrous metals for long life long runs For metals aluminum is generally the material of choice Molds should be designed with radii at least two times the material thickness and draft angles of 5 or greater Vacuum holes should not exceed 1 32 in diameter Since the Celtec sheet may shrink in the extrusion direction it is necessary to use a clamping ring preferably with anti slip devices The Celtec material must be cooled completely before it is removed from the mold Heat Welding Celtec can be joined using fusion welding ultrasonic welding and hot gas welding For Celtec thicknesses over 6 mm butt fusion welding is recommended In general the pressure used for solid PVC must be reduced for expanded PVC Exact recommendations are dependent on the length and thickness of the Celtec part to be welded For more precise information
42. es of various types within the following guidelines Figure 11 Relief angle 5 to 10 Rake angle 10 to 0 Cutting speed 3 000 to 3 500 feet per minute Cutting feed 0 12 inches per revolution 4 Figure 1I Rake Angle 10 0 Helical milling cutter Relief Angle 5 10 Routing Celtec material can be easily routed using multi fluted carbide tools on standard woodworking routers Standard tools and machines can be utilized without having to alter equipment bits Figure 1m Adjust feeds and speeds as needed to achieve the best edge finish on the Celtec parts www acplasticsinc com Chapter 1 Processing 1 15 4 Figure 1m Standard router bits Edge Finishing Edge finishing of Celtec can be accomplished using various sanding filing or grinding tools such as a sander or file Be careful to not overheat surfaces Slight cell structure may be visible on cut edges of the Celtec material Important When machining Celtec material secure hold downs so that the force is spread out over a large area Copyright O 2005 A amp C Plastics Inc 1 16 Celtec User Guide Manufacturers Sawing Equipment Forrest Manufacturing Company 973 473 5236 457 River Road www stores yahoo com forrestman Fax 973 471 3333 Clifton NJ 07014 Hendrick RWH Industries Inc 978 741 3600 36 Commercial Street www hendrickmfg net Fax 978 744 0242 Salem MA 01970 Holzma US 704 861 8239 1200 Tulip Drive www stilesmachi
43. hesive Sheet The preferred methods of photomounting on Celtec sheets are cold mounting using cold roller laminators such as Warman Greig Greig or Sealeze presses cold vacuum mounting with VacuSEAL presses and hand lamination The sophisticated Greig press is used by large photo labs while the Sealeze press is more commonly found at small commercial labs The VacuSEAL press is utilized primarily by photo shops Because Celtec material may warp when heated above 140 F or when heated from one side only it cannot be dry mounted or hot mounted Laminating Celtec is an ideal material for applications that require lamination This section provides preparation information processes as well as detailed instructions for the various types of lamination that can used with Celtec Because prints are one of the most frequently laminated materials the sections that follow will generally refer the lamination of a print although many other materials can be used www acplasticsinc com Chapter 5 Special Applications 5 3 Because Celtec material may warp when heated above 140 F or when heated from one side only it cannot be used in any lamination process requiring heat Adhesion For best results the Celtec material should be cleaned with isopropyl alcohol prior to adhesion and allowed to dry thoroughly When laminating with pressure sensitive adhesives a force of 25 40 psi is required Figure 5b Proper spacers
44. ignment of the adhesive roll too much pressure or rollers that are not parallel Trapped dirt or lumps of hardened adhesive common with Cibachrome or glossy prints may create small bumps in the finished product In order to prevent these problems equipment used for Celtec lamination must be kept clean Figure 5c Use a fresh roll or sheet of transfer adhesive if bumps are caused by hardened adhesive Dirt problems can be minimized by using an ionizing static eliminator Using prints or other materials made with a paper 0 007 or thicker can help prevent strike through Too great a pressure may cause wrinkles pde ere dirt or hardened adhesive causes lumps Print Adhesive Sheet Figure 5c To prevent surface blemishes and wrinkles keep equipment clean www acplasticsinc com Chapter 5 Special Applications 5 5 For best results wipe down the back of the print and the face of the Celtec mount with a clean dry cloth before it passes through the roll nip Whether the finished product is to be used indoors or outdoors a clear high gloss overlay will help protect against fading as well as enhance the color MACtac IP 7000 Perma Color overlay and Seal Print Shield have proven to work effectively with Celtec Do not use overlays clear coatings or sprays that contain solvents as they may cause blistering Laminating Techniques Four techniques are recommended for laminating materials to Celtec as described i
45. ilable in 500 foot coils with one presharpened edge The thickness of the strip steel can be specified by a point designation with one point equaling 0 014 inches To cut Celtec with an SRD the recommended thickness of strip steel ranges from 2 points 0 028 inches to 6 points 0 084 inches The most commonly used strip steel thicknesses for cutting Celtec are 3 points 0 042 inches and 4 points 0 054 inches To construct the die lengths of strip steel are first cut from the coil These cut lengths called knives are then bent to the desired shape or pattern to be cut and embedded in a maple block called a die body www acplasticsinc com Chapter 1 Processing 1 3 The SRD assembly is mounted under the top platen of the press The Celtec sheet is then placed on a steel bottom platen When pressure is applied the knives of the SRD are forced through the Celtec producing a cut Hydraulic platens or clicker presses are used to supply the necessary pressure for the cut After the cut the platens are separated and the sheet or cutouts are removed At this point any finishing work required can begin To help eject the cut Celtec strips of a resilient compressible material such as open cell foam rubber can be glued next to the knives Figure 1b The strips should extend about 1 16 inch beyond the cutting edge of the knife Strips of the same material can be used to secure the Celtec sheet in position by gluing the strips
46. in an elongated slot or an oversized hole is recommended so that the material can expand or contract if fluctuations in temperature occur Figure 2b For best results use oversized washers or grommets in combination with screws www acplasticsinc com Chapter 2 Fastening 2 7 4 Figure 2b Elongated or oversized holes are recommended for use with a screw or bolt Celtec Screws should be tightened and then retreated slightly to allow the Celtec material to expand or contract as necessary In small panels under 18 inches or in temperature controlled environments allowing for expansion and contraction is not mandatory Mechanical failures in heating or cooling systems and other unexpected factors can however affect temperatures radically and may cause unanticipated expansion or contraction Nailing is suggested for small thin panels of Celtec material To use larger nails and screws holes should be placed at least one inch from any edges and predrilled Figure 2c Celtec is more brittle in colder temperatures so if work is being completed outdoors in low temperatures be careful to avoid possible fracturing of the Celtec material Copyright 2005 A amp C Plastics Inc 2 8 Celtec User Guide 4 Figure 2c Screwing recommendations for Celtec Installation Celtec is manufactured as an extruded PVC product with a directional grain ruming the entire length of the sheet This manufacturing pr
47. istant paint such as a two part polyurethane Because foamed PVC in white is often 20 to 30 less expensive than other colors various surface treatments using white foamed PVC can be affordable alternatives A second basic fact of foamed PVC boards is that color will vary somewhat from manufacturer to manufacturer from extrusion machine to extrusion machine as www acplasticsinc com Chapter 6 Engineering Specifications 6 5 well as from batch to batch A common manufacturing range for color variation is three Delta E units Many people believe that more than three Delta E units is noticeable Also the perception of color can vary from the top of a sheet side A to the bottom side B Inherent in the manufacturing process for foamed PVC is some variation of surface texture between the top and bottom of a sheet This may result in a different gloss level and the appearance of a slight difference in color even though the color is homogeneous throughout the entire sheet Subtle lines created by the extrusion process may also appear on one side of the material again giving a slightly different perception of color or consistency The strong demand for foamed PVC has led manufacturers to make it available in a variety of stock colors custom colors are also available Yet many of the issues affecting color in foamed PVC must be considered differently for custom colors than for standard colors Weathering of Foam
48. knife penetration may vary throughout the cut In order to produce a uniform cut the backup plate should be built up to achieve even penetration by the die The process of building up the backup plate to eliminate unevenness is called make ready as explained below Make ready steps for die cutting 4 Securely mount the SRD on the upper or lower platen as required ensuring that it will not move during the die cutting 2 On the opposite platen firmly mount the die cutting plate which should be 1 16 to 1 8 inches thick 3 Using thin paper such as Kraft wrapping paper prepare the make ready sheet which should be the exact size of the cutting plate Position the make ready sheet on top of the cutting plate IMPORTANT Before proceeding make certain that the press is not out of square Figure 1g www acplasticsinc com Chapter 1 Processing Correct a Figure 1g Proper alignment of SRD die presses is very important in obtaining optimum results 4 Engage and adjust the press so that the die just touches or kisses the cutting plate The die should leave an impression on the paper without leaving an impression on the plate Usually only about two thirds of the die pattern will leave its impression on the paper Do not attempt to make a complete impression of the die cut during this step 5 After the kiss cut transfer the make ready sheet from the top of the cutting plate to beneath the cutting plate
49. l Avenue www codamount com Fax 201 825 8133 Mahway NJ 07430 Copyright O 2005 A amp C Plastics Inc 5 14 Celtec User Guide This page intentionally left blank www acplasticsinc com Engineering Specifications Field performance of Celtec indicates excellent weatherability in outdoor applications under various environmental conditions Tests are currently being conducted to accurately determine the long term environmental effects of Celtec Weatherability Effects of Outdoor Exposure Tensile Strength Virtually no tensile strength changes have been noted in prolonged environmental exposure tests Color Dark colors are not recommended because they absorb heat energy and can exceed use temperatures UV Stability of White Celtec One of the many advantages of Celtec expanded PVC sheet is its ultraviolet durability Celtec is made with the same ingredients found in most weatherable vinyl siding and window materials While the concentration of these ingredients is not the same Celtec will provide years of minimal color change In addition Celtec will not warp rot crack or peel like wood products in similar outdoor exposures Celtec was weathered in a QUV weatherometer by Vista Chemical Company along with a standard pipe compound vinyl siding and another major expanded PVC brand The test replicated two years of exposure outdoors in Arizona Celtec in 3 mm and 6 mm thicknesses retained more of their respective c
50. lightweight foamed PVC sheet Celtec is excellent for the highly specialized needs of producing signage and displays as well as booths and stage sets Other applications include photo mountings and building materials As a USDA approved product Celtec can be used wherever food is processed or sold Celtec Displayboard is free of lead barium and cadmium And as the first foamed PVC to be U L Classified Celtec meets all three U L 1975 fire test requirements minimizing the risk of both heat conduction and fire www acplasticsinc com Product Availability All information contained herein is accurate to the best of our knowledge and is provided without liability or commitment whatsoever We recommend that you confirm the suitability of our product by carrying out tests under your local conditions and using your own mechanical equipment Custom colors sizes gauges tolerances and formulations are available upon request and with a minimum order Actual color may vary from production run to production run Because of limitations in printing precise color may be different from the samples shown below Color Samples PMS numbers are an approximation to provide designers with a color range Actual color may be different from printed samples shown below iv Celtec User Guide www acplasticsinc com www acplasticsinc com Color Sample PMS RGB CMYK HTML C 0 M R 0 G 0
51. ly small items utilizing a transfer adhesive Figure 5h 1 Using a sheet of transfer adhesive having both sides covered by release paper peel away and fold back the release paper 1 2 inch from one edge 2 Place the edge of the print to be laminated on the exposed adhesive 3 Remove the rest of the release paper while lifting the print slightly to avoid contact with the adhesive then use a roller or a squeegee to smooth the print evenly onto the adhesive 4 Figure 5h This cross section illustrates cold laminating by hand using transfer adhesive sheets with release paper Adhesive 4 With the print facing down and the remaining release paper facing up smooth out any excess air from between the print and the adhesive with a squeegee 5 To laminate the print to the Celtec material peel away and fold back the release paper 1 2 inch from one edge 6 Placing the print evenly on the Celtec material tack the exposed adhesive to the Celtec 7 Gradually remove the liner while pressing closely with a hand roller or a squeegee to eliminate any air bubbles until the entire print has been laminated Figure 51 www acplasticsinc com Chapter 5 Special Applications Release Paper Celtec Adhesive Figure 5i Press the print firmly with a hand roller or a squeegee while rolling in the same direction For best results remove only a small section of the liner at a time approximately 12 or less
52. m Male Form Male Form a Figure 3c Conventional pressure forming accomplished with a two piece mold and drape forming When using radiant heaters be careful not to overheat the surface If the Celtec material is over 4 mm thick both sides of the sheet should be heated Figure 3d When heating from only one side the top heater should be set at 750 F or below With two sided heating the top heater should be at 750 F and the bottom at 650 F If using an air circulated oven the temperature should be between 260 F and 280 F Copyright 2005 A amp C Plastics Inc 3 4 Celtec User Guide Top Heater 750 4 Figure 3d yx 7 a E e ol or thicker s Y Bottom Heater 650 After the Celtec is heated place it immediately into the mold The male mold should have a draft angle of at least 5 degrees Depending upon the part to be formed the Celtec material may need to be larger than the mold to allow for shrinkage and or clamping Because there are limits to the Celtec material s ability to stretch while still producing aesthetically acceptable results the depth of the part that can be successfully created will depend upon both the mold and the part s design When creating or selecting a mold for Celtec material it is important to use a mold without sharp corners Cycle times for Celtec are very fast approximately 15 to 20 seconds per millimeter of thickness with radiant heaters and 30 to 40 seconds p
53. n the following sections Depending upon the type of applications and the equipment available one or more of these processes may be appropriate for a particular application None of these processes involves the use of heat Because Celtec may warp at temperatures above 140 F or when heated from one side only it cannot be dry mounted or hot mounted The four recommended lamination techniques for Celtec are Cold laminating with a press using adhesive backed paper Cold laminating using Vac U Mount press Hand laminating using transfer adhesive Hand laminating using spray adhesive Cold Laminating with a Press using Adhesive backed Paper This process is most frequently used by commercial photo labs with Greig or Sealeze presses and transfer adhesives such as MACtac IP 2000 Photomount or Seal Print Mount Either of two types of liner films a single release liner film or a double release liner film can be used for this process The basic process for laminating with a press using adhesive backed paper is described in the following section Copyright 2005 A amp C Plastics Inc 5 6 Celtec User Guide 1 Set the roller pressure properly for the thickness of the pre coated mounting substrate 2 Place the mounting substrate on a flat surface and expose approximately one inch of the adhesive by peeling back the release paper Figure 5d Fold back the release paper making an even crease across the paper 4 Figure 5d
54. ncnn ron n ron nrnnnrnn ninos 6 9 Standard Specifications cccccceescessceseceseceseceseceeeseeeseeseeseeeeeesseceseceaecaecaeecaeecaeeeaeeeseseeeeereneseneeses 6 11 Chapter 7 Material Safety Data L Product Identification an A AA ea 7 1 II Components and Hazard Classification cccccsceesseesceesceesceeeceseceseceaecaeeeeeeeseeeeneeeneeneenaeenaes 7 1 WI Physical Data ta A a E 7 2 IV Fire and Explosion Data id tee eevee 7 2 V Health Hazard Informations ii att 7 3 VEREDA ot 7 3 VIL Spill Or Leak Procedures a asa 7 4 VIII Special Protection Information nennen geeni i e i iR E E E REE 7 4 TX Shipping Transfer and Storage sa 7 4 Introduction Celtec Displayboard is a lightweight expanded foam polyvinyl chloride PVC sheet material that combines the chemical resistance and fabrication capabilities of rigid PVC with a closed cell expanded core Celtec Displayboard is manufactured in gauges from 1mm through 25mm 1 for use in an expanding variety of markets The structure of Celtec is a closed cell foam that does not absorb moisture These features combined with its light weight and insulating characteristics sound and thermal make Celtec the choice material for exterior and harsh moisture environments Celtec Displayboard has a high quality surface for both screen and direct Digital Printing using the flatbed feed technology as well as painting and applying vinyl graphics It is lightweight for easy
55. nery com Fax 704 867 4140 Gastonia NC 28052 Die Cutting Equipment Brantzen and Klugy 715 483 3265 539 Blanding Woods Road Fax 715 483 1640 St Croix Falls WI 54024 J A Richards Company 800 253 3288 903 Pitcher Street www jarichards com 616 343 4684 Kalamazoo MI 49007 Fax 616 343 9133 Thomson National Press Co 508 528 2000 115 Dean Avenue www thethomsongroup com Fax 508 528 6869 Franklin MA 02038 Router Equipment Onsrud Cutter LP 800 234 1560 800 Liberty Drive www onsrud com 847 362 1560 Libertyville IL 60048 Fax 800 557 6720 www acplasticsinc com Fastening In this chapter various methods of fastening Celtec are covered as well as important details to consider during the fabrication process With the numerous uses for Celtec and the differing environments of service 1t is important to take into account Celtec s thermoplastic properties during fabrication and installation Notch Sensitivity When designing a Celtec part it is important to maintain a smooth radius corner along the perimeter edge or in slotted areas Figure 2a Using a sharp corner angle or scored line is not recommended and can result in fracturing of the Celtec material With thinner sheets of Celtec radii as small as 1 8 generally can be cut without difficulties Celtec User Guide 4 Figure 2a Sharp angles should be avoided in designing Celtec parts The correct procedure is to maintain a smooth inner or outer radius
56. ocess gives Celtec greater flexural strength in the direction of the extrusion Because of this characteristic flag type signs should be cut so that the grain direction is horizontal to the anchor point Figure 2d This precaution permits the Celtec material to flex and withstand wind pressure Grain Grain WRONG Correct www acplasticsinc com Chapter 2 Fastening 2 9 a Figure 2d The grain of the Celtec material should be perpendicular to the attachment point Failure to cut and attach the material in the proper direction may cause fracturing to occur particularly in narrow signs Bonding and Adhesives Celtec to Celtec or other PVC material For bonding Celtec to itself or another PVC material a solvent based adhesive system used for rigid non expanded PVC will provide the best results Solvent based adhesives are sold through various suppliers Proper ventilation and a clean working environment are essential for this type of bonding When bonding large panels face to face avoid using solvent based adhesives which will not cure properly Celtec to various substrates There are numerous types of adhesives that can be used with specific substrates Contact epoxy rubber base and urethane adhesive systems are all acceptable For best results test the selected adhesive for suitability in a particular application before general use Parts to be joined should fit without forcing and be prepared with appropriate cl
57. olor than did the major competitors brands of expanded PVC sheet for the same thicknesses 6 2 Celtec User Guide Vycom Weatherability Comparison Test Vistas 3mm Celtec 3mm Sintra Weather Resistant 0 Hours 250 Hours 500 Hours 750 Hours 6mm Celtec Gmm Sintra Vista Pipe 0 Hours 250 Hours Stress Some silkscreen inks contain solvents that can cause environmental stress cracks For more information refer to the desired manufacturer s ink and solvent charts www acplasticsinc com Chapter 6 Engineering Specifications 6 3 Vycom WEATHERABILITY Comparison Test XENON EXP 300 MJ 12 MONTHS FLORIDA 6 4 Celtec User Guide Color in Foamed PVC Foamed polyvinyl chloride PVC has become one of the most popular materials for a wide range of projects whether the application involves exhibits and displays signage screen printing photo mounting or various OEM fabrications Yet like other materials foamed PVC has unique characteristics and correct information about the nature of the product will contribute to more successful projects Information about color in foamed PVC can be especially helpful in deciding how to use this type of material to its best advantage Closed cell foamed PVC is moisture resistant and manufacturers recommend it for various time periods outdoors as well as for indoor use The recommended outdoor time periods are directly related to the degree
58. or varnish to be tested for adhesion Let dry for a minimum of 48 hours 2 Using a knife with a replaceable blade make 11 parallel cuts 1 16 apart At a 90 angle to the first set of 11 cuts and crossing them make a second set of 11 parallel cuts also 1 16 apart Figure 4b The purpose of the cuts is to break the film plane of the paint or varnish www acplasticsinc com Chapter 4 Graphic Applications 4 Figure 4b Make 11 parallel horizontal and parallel vertical cuts 1 16 apart 3 Pressing firmly apply a 1 2 wide strip of strong tape i e Scotch brand across the scored area Figure 4c 4 Figure 4c Place a 1 2 wide strip of strong tape over the cross hatched area aligning the edge of the tape with a cut line Tape 4 Immediately and in one rapid motion remove the tape by pulling it back at a 180 angle parallel to the Celtec sheet Figure 4d Copyright 2005 A amp C Plastics Inc 4 6 Celtec User Guide 4 Figure 4d Remove the tape at a 180 angle in one rapid motion 5 Proper adhesion has been obtained if paint remains on the Celtec after the tape is removed Relative paint adhesion comparisons can also be made by inspecting the amount of paint remaining in the area that was covered by the tape Application Concentrated forms of paints and varnishes should be thinned before use Follow the manufacturer s guide and recommendations For best results conventional air
59. processed Load the supply roll of pressure sensitive adhesive such as Sealeze Print Mount or Print Mount Ultra Pull approximately 12 inches of adhesive film forward off the roll Rest the film adhesive side up on top of the pressure roller Create a leader board by cutting a piece of substrate slightly larger than the width of the adhesive film and approximately four to six inches long Lay the leader board across the adhesive film and smoothly adhere the bottom of the leader to the adhesive Place the direction switch in the forward position and the speed control on medium Pull the leader down and push it between the rollers Depress the foot switch and feed the leader between the rollers approximately three to four inches Be sure that the adhesive stays firmly adhered to the leader Once this process has been completed referred to as stringing the web and the adhesive is feeding without wrinkles the laminator is ready for production To coat feed a substrate behind the leader board and between the rollers while depressing the foot switch Feed until the substrate exits the rollers and automatically stops feeding At this time another substrate may be fed between the rollers for coating This process is suitable for films with a paper release liner such as Sealeze Print Mount and Print Mount Ultra and leaves a 3 8 to 1 2 gap between the coated substrates to facilitate the trimming process
60. ration 455 W Victoria Street Compton CA 90220 USA 310 898 3300 Fax 310 898 3392 Toll free 800 421 2677 www ipscorp com o o Z o N a www acplasticsinc com Chapter 2 Fastening 2 13 Adhesives and Manufacturers The first table below lists several adhesives and their bonding applications for materials commonly used in fabricating Celtec products The second table contains contact information for the manufacturers of those products Additional adhesive manufacturers are listed in the third table The listed adhesives and manufacturers are for informational purposes only Please perform the appropriate tests to ensure that the materials will produce the desired results Celtec Recommended Adhesives and Applications Celtec to Manufacturer Adhesive al al 3M Adhesives Division aa Scotch Weld 2216B A 3549 B A aa bond 3M Scotch Grip 4475 Fast Bond 30 Neutral nonstructural bond Plastics Other Hardboard Pressure Laminates Fast Bond 30 NF Green Contact Adhesive Fast Bond 2000 Adhesive Daubond 6552 Daubond 8050 Unidex Solvent Epoxy Dow Corning Corp 739 Plastic Adhesive AEREA O GE Silicones Silicone Il Window and Door Henkel Loctite Corporation ae er 454 Surface Insensitive ae er Gel Speedbonder 324 325 326 x structural bond Oatey Co PVC and ABS and CPVC All ABS Purpose Cement CPVC National Casein eves gt ee A Copyright O 2005 A amp C Plastics Inc
61. ry production is ready to begin If roughly cut areas persist repeat the taping procedure www acplasticsinc com Chapter 1 Processing 1 11 Make Ready Tips When dies include intricate patterns and or sharp bends more pressure will be required to make the cut Additional tape shims to build up the cutting plate may be needed in these areas Figure 11 4 Figure 1i Tape shims may be required where patterns to be die cut are intricate or have sharp bends X and corners Make Ready Sheet withTape Shims Once the die is cutting cleanly the make ready sheet should last throughout the entire job If necessary however small imperfections can be rectified by applying additional cellophane tape to the specific problem areas IMPORTANT Do not attempt to remedy cutting problems by shimming the back of the die It is difficult to locate the exact area for tape placement and in most cases the die will wear through the tape and ruin the make ready sheet On completion of the job file the make ready sheet together with the die This will reduce setup time if the job is rerun Copyright 2005 A amp C Plastics Inc 1 12 Celtec User Guide Sawing Circular Saws For Celtec sheets 3 mm and thicker carbide tipped triple chip ground type circular saws can be used Figure 1j The following settings are recommended Rake angle 0 to 15 Clearance angle 10 to 20 Cutting speed 8 000 to 12 000 f
62. s in Air by Volume ee Extinguishing Media Water spray fog foam dry chemical or CO2 Special Fire Fighting Procedures Cool exposed equipment with water spray Use self contained breathing apparatus if fighting fire in confined spaces Unusual Fire and Explosion Hazard PVC evolves hydrogen chloride carbon monoxide and other toxic gases when burned Exposure to combustion products may be fatal and should be avoided www acplasticsinc com Chapter 7 Material Safety Data 7 3 V Health Hazard Information Pertains to dust or chips as a by product of fabricating finished sheet Eyes Immediately flush with plenty of water Call a physician if irritation persists Flush skin with plenty of water Remove contaminated clothing Call a physician if irritation persists Wash clothing before reuse Inhalation Remove to fresh air If exposed to high concentrations of dust physical irritation of the eyes This material is not expected to present a hazard to the intact skin Molten sheet will produce thermal burns Inhalation Under normal conditions and with normal use no inhalation hazard is presented Please refer to Section VI Fire and Explosion Data Ingestion No significant health hazard can be reasonably anticipated None established ACGIH TLV of 10 mg m total dust as an 8 hour TWA is recommended Skin Contact A review of the pertinent literature did not reveal specific information for PVC Eye Contact A revie
63. sticsinc com Chapter 2 Fastening 2 3 Calculations for thermal expansion and contraction should be made for both the width and the length of the Celtec material Celtec should not be used in areas that exceed 140 F at which temperature the Celtec will soften and change dimension permanently Dark colors are generally not recommended for outdoor use as they absorb heat energy and can easily exceed the maximum allowable temperature of 140 F When exposed to direct sunlight white Celtec will generally show a surface temperature 10 to 20 higher than the actual air temperature Celtec Thermal Expansion Contraction Worksheet The following worksheet will help calculate the correct size to cut a Celtec part in order to allow for potential expansion and contraction after installation 1 Highest expected temperature in the environment in which the Celtec part will be used in degrees Fahrenheit 3 Total temperature difference subtract line 2 from line 1 4 Total length of Celtec part in inches in 5 Total amount of expansion line 3 x line 4 x 0 00004 in F 2 Approximate temperature of the Celtec part at the time it was cut in F degrees Fahrenheit in Copyright 2005 A amp C Plastics Inc Celtec User Guide Contraction 1 Approximate temperature of the Celtec part at the time it was cut in degrees Fahrenheit 2 Lowest expected temperature in the environment in which the Celtec part
64. t requirements Fire Characteristics The oxygen index value of Celtec is 35 Materials with a value of 28 or higher are considered self extinguishing For comparison oak carries a value of 23 and birch carries a value of 21 Health and Environmental Celtec contains no lead cadmium barium or zinc heat stabilizers Celtec is made only with tin which means that there are no special health environmental or waste disposal problems Copyright 2005 A amp C Plastics Inc 6 12 Celtec User Guide This page intentionally left blank www acplasticsinc com Material Safety Data l Product Identification Polyvinyl Chloride PVC Vintec I Vintec II Celtec sheet Synonyms Vinyl Polymers CAS Number s 9002 86 2 ll Components and Hazard Classification Inert Fillers 0 30 CaCOs TiO2 Heat Stabilizer Organotin Compounds Lubricants 0 4 Calcium Stearate Paraffin Polyethylene Polyamide Compounds or Esters This product is an article as defined in 29 CFR 1910 1200 It will not result in exposure to hazardous chemicals under normal conditions of use This product is not subject to the reporting requirements of Section 313 of Title lll of the Superfund Amendments and Reauthorization Act of 1986 and 40 CFR Part 372 7 2 Celtec User Guide lil Physical Data Appearance and Odor Finished sheet IV Fire and Explosion Data Flash Point Test Method Autoignition Temperature Flammable Limit
65. taking care that it is placed in the identical position in the press Keeping the paper in the press will ensure that the exact knife depth required to cut the Celtec cleanly as established in Step 4 with the paper in place is maintained Figure 1h Copyright 2005 A amp C Plastics Inc 1 10 Celtec User Guide 4 Figure 1h The make ready sheet must be identical to the size of the platen Make Ready Sheet AN 6 Place a sheet of Celtec in the press and strike a part If upon inspection you find an incomplete impression the press can be lowered Be sure however that the die just contacts the cutting plate 7 Examine the cut Celtec If portions of the perimeter have rough edges follow the steps below a Remove the make ready sheet from beneath the cutting plate Using the die cut sample made in Step 6 as a guide place single layers of cellophane tape on the make ready sheet in all areas where the cut is not clean This selective taping will improve the cutting action in the problem areas Use a single layer of tape only Do not overlap the tape strips or add tape to areas that are already cutting cleanly Tape strips or shims may also be necessary in areas in which the pattern to be die cut is intricate or has sharp bends and corners b Re insert the taped make ready sheet under the cutting plate and strike another sample making certain that the cut just penetrates the Celtec sheet If the cut is satisfacto
66. th Celtec surface is ideal for all types of graphics and it requires little surface preparation or surface treatment General Considerations To ensure best results for any graphic application using Celtec consider the following factors that may affect the finished installation Environmental and safety concerns Weathering Chemical resistance Ease of application Cost effectiveness Hardness Scratch resistance Priming or multicoat paint applications Because of the wide range of products available select paints and varnishes carefully for each application Initial testing of the selected paint or varnish system is recommended before a production run Cleaning Pretreating Before screen printing painting or varnishing Celtec the surface area should be cleaned with isopropyl alcohol and a clean white cloth Depending on the specific application certain pretreatments may also be required as described in the following sections 4 2 Celtec User Guide Digital Flatbed Printing Celtec provides an excellent surface for screen printing and accepts a wide range of inks When silkscreening on Celtec crisp full coverage is achieved with printing inks that normally would be used for other rigid PVC products Celtec Displayboard in the 10 mm thickness and above provides an extremely smooth surface for printing For best results when screen printing be sure that the Celtec sheet has been degreased and cleaned
67. ticsinc com Chapter 1 Processing 1 5 A thinner gauge knife will not require as high a sheet temperature to produce equivalent quality die cuts because a thinner knife encounters less resistance and creates a cleaner edge on the cut Celtec A thicker knife will require that the Celtec be heated to make it more flexible and less brittle in order to create a similar die cut quality The appropriate die knife thickness is directly related to the thickness of the Celtec material being cut If the knife is too thin for the thickness of the Celtec the knife is prone to breaking If it is too thick the knife tends to deform the Celtec material When die cutting Celtec sheets use the following guidelines to determine the appropriate knife size For most common applications a 3 point or 4 point 0 042 or 0 056 knife is recommended For cutting complex parts in sheet material less than 4 mm a 2 point 0 028 knife is recommended For sheets over 6 mm or for wide separating cuts a 6 point 0 084 knife is recommended Correct bevel selection Knife bevels vary according to length and type Bevel length is defined as the distance from the tip to the end of the honed surface When cutting Celtec the length of the bevel should be between 3 16 and 1 4 inches Figure Ic 4 Figure 1c Bevel length j Bevel Length 3 16 1 4 Copyright O 2005 A amp C Plastics Inc 1 6 Celtec User Guide In general the
68. ulti Purpose Solvent based 200 305 9700 Solvent based 200 305 1600 UV 355 390 1700 UV 355 390 3600 Sericol Inc Uviflex 390T LE Twill 70 90 UX MX UX TH Fascure 390T LE Twill 70 90 4 Pi e 390T LE Plain Plastical Silkscreen Ink Manufacturers Coates Screen 800 333 4657 2445 Production Drive www coates screen com 630 513 5348 St Charles IL 60174 Fax 630 513 1655 NazDar 800 767 9942 8501 Hedge Lane Terrace www nazdar com 913 442 1888 Shawnee KS 66227 Fax 913 442 2296 Sericol Inc 800 sericol tech service 1101 W Cambridge Drive www sericol com 913 342 4060 Kansas City KS 66103 Fax 913 342 4761 www acplasticsinc com Chapter 4 Graphic Applications 4 9 Recommended Paints 7 n r A Blue River Hydroflex P IR Water Based X7000 Clean Coating Urethane Water High Perf A IR Acrylic Urethane X7000 Clean Water Carbit Paint Carbithane 11 Acrylic Polyurethane 11C2 T 64 Series Low VOC Carbithane 12 Acrylic Polyurethane 12C0 T 64 Series MAP Acrylic Polyurethane 43 270SP 45 280SP 45 280SP 43 621SP 45 290SP 45 290SP 6372SP 6372SP 6396SP 6396SP Matthews Satin MAP Acrylic Polyurethane 43 270SP 45 280SP 45 280SP 43 621SP 45 290SP 45 290SP 6372SP 6372SP 6396SP 6396SP VOC MAP Acrylic Polyurethane 285 800SP 6300SP 45 280SP 6301SP 45 290SP 6302SP 6372SP 6396SP Satin VOC MAP Acrylic Polyurethane 285 320SP 6300SP 45 280SP 6301SP 45 290SP 6302SP 6372SP 6396SP RenoCoatings Prolux Series 32000
69. ults test the machine setups and cutting processes before beginning production Celtec s density is approximately half the density of conventional PVC which makes it compress relatively easily Die Cutting When Celtec sheets are used for mass producing flat shapes or cutouts die cutting is the most commonly employed fabrication technique Celtec is an ideal material for die cutting producing a clean smooth edge without splintering or cracking Die cutting is recommended for a wide range of applications including letters openings within larger sheets of Celtec 1 2 Celtec User Guide puzzle pieces and assemblies that fold into three dimensional shapes such as point of purchase POP displays Figure 1a Figure 1a Die cutting is recommended for a wide range of applications such as letters puzzle pieces and assemblies or displays finished into 3 D shapes To improve processing efficiency Celtec sheets can be painted printed or silkscreened prior to die cutting After die cutting the Celtec sheets or pieces can be finished by heat bending fastening gluing or machining Test the die cut suitability of the Celtec material before painting or silkscreening an entire production run Of the various die cutting methods available the most frequently used method is Steel Rule Die Cutting in which the steel rule die SRD functions very much like a cookie cutter SRDs are constructed from one inch wide strip steel ava
70. w of the pertinent literature did not reveal specific information for PVC Inhalation Rodents exposed by the dietary or inhalation route for 6 to 24 months have shown no significant toxicological effects IN ECN Special Precautions AVOID INHALATION OF COMBUSTION PRODUCTS VI Reactivity Data Conditions Contributing to Instability Not applicable Incompatibility Not applicable Hazardous Decomposition Products Hydrogen chloride and other toxic fumes generated with combustion Conditions Contributing to Hazardous Not applicable Polymerization Copyright O 2005 A amp C Plastics Inc 7 4 Celtec User Guide VII Spill or Leak Procedures When producing chips or dust from fabricating PVC sheet sweep scoop or vacuum and remove Dispose of only in accordance with local state and federal regulations VIII Special Protection Information Pertains to dust or chips as a by product of fabricating finished sheet General ventilation when fabricating and nuisance dust control particulate filter respirator should be used Other Clothing and Equipment IX Shipping Transfer and Storage Non hazardous for transportation purposes Usual Shipping Containers Palletized sheets o Storage Transport Temperature Sustained temperatures above 150 F may cause slow degradation Electrostatic Accumulation Hazard Yes www acplasticsinc com
71. while adhering the print to the Celtec Hand Laminating using Spray Adhesive For small shops or display makers without access to equipment this method is recommended for the lamination of flat relatively small items utilizing a spray adhesive such as 3M Vac U Mount Figure 53 4 Spray the adhesive such as Vac U Mount on the back of the piece to be mounted keeping the spray six to eight inches from the surface If using a double coat of adhesive the second coat should be applied in a direction perpendicular to the first coat For bonding most art materials the adhesive is typically applied only to one surface preferably the back of the print Copyright 2005 A amp C Plastics Inc 5 12 Celtec User Guide 4 Figure 5j Mounting a print to Celtec using Spray Adhesive a spray adhesive 2 Allow the spray to dry between two to four minutes before mounting so that the adhesive becomes tacky 3 Place the adhesive side of the print or other item on the Celtec surface pressing smoothly from the center of the piece to the edges in order to eliminate any wrinkles and trapped air immediately If blisters occur from trapped solvent allow the adhesive to dry slightly longer than four minutes for mounting 4 Place a clean sheet of Celtec over the laminated piece to weigh it down Although the bond should be at maximum strength after fifteen minutes allow 24 hours before exposing the piece to any sudden temperature or humi

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